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Full text of "IS 12753: Electrogalvanized Coatings on Round Steel Wire"

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IS 12753 (1989) : Electrogalvanized Coatings on Round Steel 
Wire [MTD 7: Light Metals and their Alloys] 




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Satyanarayan Gangaram Pitroda 
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PROTECTED BY COPYRIGHT 



IS 12753 : 1989 

(Reaffirmed 2001) 

Indian Standard 

ELECTROGALVANIZED COATINGS ON 
ROUND STEEL WIRE — SPECIFICATION 



UDC 669'14-426-2 : 669-587 



(g) BIS 1990 

BUREAU OF INDIAN STANDARDS 

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG 

NEW DELHI 110002 

February 1990 Price Gnmf t 



MetiiUic and Non- Metallic Finishes Sectional Committee, MTD 20 



FOREWORD 

This Indian Standard was adopted by the Bureau of Indian Standards on 20 July 1989, after the 
draft finalized by the Metallic and Non-Metallic Finishes Sectional Committee had been aj)proved 
by the Metallurgical Engineering Division Council. 

Electrogalvanizing of steel wires is a growing industry; however it is yet to intensify its applica- 
tions. Electrolytic process has not found wider acceptance in comparison to the zinc coating by 
hot-dipping process [covered by IS 4826 : 1979 *Hot dipped galvanized coatings on round steel wire 
{first revision )' ], because of the initial high capital cost of installation and of skilled personnel. 

Advantages of electrogalvanizing over the hot dip process are: 

a) Closer control of coating thickness and, therefore, saving of zinc; 

b) Electrogalvanized zinc is pure, more concentric and uniform and is more versatile in use; 

c) No ash or zinc dross is formed; 

d) Heavier coatings ( up to 1*2 kg/m^ ) is possible only with electrogalvanizing; 

e) Plant can be shut down quickly and restarted quickly; and 

f) Electrogalvanized steel wires are better for further drawing and stranding. 

However, hot dip galvanizing requires less space and gives lustrous zinc coatings, while corrosion 
protection for both types is similar. In order to rationalize the requirements of different types of 
galvanized wires, coatings have been grouped into three types, that is, heavy, light and medium. 
For general guidance, Annex A indicating applicability of various types of coatings on different 
wires has been included.' 

For the purpose of deciding whether a particular requirement of this standard i5 complied with, 
the final value, observed or calculated, expressing the results of a test or analysis, shall be rounded 
off in accordance with IS 2: 1960 'Rules for rounding off numerical values { revised y. The 
number of significant places retained in the rounded off value should be the same as that of the 
specified value in this standard. 



IS 12753 !198>' 



Indian Standard 



ELECTROGALVANIZED COATINGS ON 
ROUND STEEL WIRE — SPECIFICATION 



1 SCOPE 

1.1 This standard covers the requirements of 
electrogalvanized coating on steel \vires of cir- 
cular section in diameters from 02 mm up to 
and including 10 mm and lays down specifica- 
tions for: 

a) mass of zinc coating, 

b) uniformity of zinc coating, and 

c) adhesion of zinc coating. 

1.2 It also lays down methods of testing for 
these properties and provides for such testing 
to be carried out before and/or after the wire 
has been used for armouring, stranding, etc. 

1.3 This standard makes no reference to the 
quality of wire itself. It does not apply to the 
articles made from wire which have been electro- 
galvanized after fabrication. 

1.4 The relevant Indian Standard governing a 
particular type of wire should refer to this stan- 
dard for specifying the requirements of electro- 
galvanized zinc coating. 

2 REFERENCES 

2.1 The following Indian Standards are necessary 
adjuncts to this standard. 

IS No. Title 

IS 1387 : 1967 General requirements for the 
supply of metallurgical materials 
( first revision ) 

IS 1956 Glossary of terms relating to 

( Part V ) : 1976 iron and steel: Part V Bright 
steel bar wire ( first revision ) 

IS 2605 : 1985 Zinc anodes for electroplating 
( first revision ) 

IS 2633 : 1986 Method of testing uniformity of 
coating of zinc coated articles 
( second revision ) 

18 3554:1966 Glossary of terms relating to 
electroplating 

IS 6745 : 1972 Methods for determination of 
mass of zinc coating on zinc 
coated iron and steel articles 

3 TERMINOLOGY 

3.1 Definitions of the terms used in this standard 



are in accordance with definitions in IS 3554 : 
1966 and IS 1956 ( Part V ) : 1976. 

4 SUPPLY OF MATERIAL 

4.1 General requirements relating to the supply 
of material shall conform to IS 1387 : 1967. 

5 GENERAL JIEQUIRT:MENTS 

5.1 Quality of Zinc 

For best results, zinc anodes of special higK 
grade ( 99'99 percent pure zinc ) as given in 
IS 2605 : 1985 are recommended in continuous 
electrogalvanizing plants. With this, the forma- 
tion of sludge is minimized while the quality of 
coatings is better maintained. 

5.2 Sometimes insoluble anodes as well as solu- 
ble zinc anodes of lesser purity, along with con- 
tinuous filtration of electrolytes are also used. 

6 MATERIALS AND MANUFACTURE 

6.1 The coatings shall be uniform, adherent, 
reasonably smooth and essentially pure zinc 
produced by electro-deposition. 

6.2 Defects in the surface of steel wire, such as 
scratches, cracks, pits, inclusions, die marks, 
etc, may adversely affect the appearance and 
performance of the electro-deposited zinc coat- 
ing. The steel wire shall be subjected to such 
polishing or bufiing operations as are necessary 
to yield deposits with the desired final lustre and 
appearance. The specifications covering the 
basic steel wire to be electrogalvanized shall be 
agreed to between the purchaser and the supplier, 
according to the applications of the electro- 
galvanized steel wires. 

6.3 Cleaning of Basis Metal 

Proper preparatory procedures and thorough 
cleaning and rinsing of the basis steel wire ( dry 
or wet drawn and/or annealed ) shall be done to 
ensure satisfactory adhesion and corrosion resis- 
tance performance of the coating. 

6.4 Electrogalvanizing 

Electrogalvanizing or electroplating of zinc on 
steel wires may be from any suitable bath like 
sulphate, sulphate-chloride, chloride', fluorobo- 
rate, etc. Continuous electrogalvanizing plants 
of horizontal line or vertical line are normally 
designed and the process of electrogalvanizing 
shall be generally as follows: 

a) Pay-off reels; 

b) Heat treatment (dipping in molten lead, 
etc ) if required; 



1 



IS 12753:1989 



c) Pickling in acid; 

d) Rinse; 

e) Electrolytic cleaning; 

f) Rinsing: 

g) Mechanical cleaner; 
h) Electro-galvanizing; 
j) Cold water rinse; 
k) Hot water rinse; 

m) Supplementary treatment, if desired: 

i) Chromate passivation ( light coating ), 
ii) Phosphate coating ( light coating); 
n) Rinsing and drying; and 
p) Take-up unit. 

NOTE — The electroplated zinc surface is attacked 
by supplementary treatments, thereby diminishing the 
coating thickness. It is recommended that extra 
thickness be built for making up this loss. 

7 COATING REQUIREMENTS 

7.1 Mass of Zinc Coating 

When determined in accordance with IS 6745 : 
1972, the mass of zinc coating shall not be less 
than the mass specified in Table 1. For Z-type 
coating, the requirements given in Table 2 shall 
apply. 

7.1.1 If the wire is tested after being used for 
stranding, armouring, barbing, binding or any 



other similar purpose, the minimum mass of 
coating shall be reduced by 5 percent. 

7.1.2 Care shall be exercised to avQid damaging 
the samples in detaching them from the finished 
strand or cable or coil. 

7.2 Freedom from Defects 

The electrogalvanized steel wire shall be uni- 
form, smooth and free from visible plating 
defects such as blisters, pits, roughness, nodules, 
cracks, burning or un plated area and shall not 
be stained, rusted or discoloured. The zinc 
coating shall be continuous and firmly adherent 
to the surface of steel. 

7.2.1 At all points more than 3 cm from a cut 
end, the coating shall withstand the number of 
dips in copper sulphate solution set out in 
Table 1 and Table 2, when subjected to the 
Preece test prescribed in IS 2633 : 1986. 

7.2.2 Finish 

Unless otherwise, stated, the finish shall be bright 
or semi-bright or dull subject to the agreement 
between the purchaser and the manufacturer. 

7.2.3 Even the best electroplating practice can- 
not remove the defects, for example, scratches, 
cracks, pits, inclusions, die^marks, etc, on the 
surface of the basis steel wire. Accordingly, the 



Table 1 



Mass of Electroplated Coating of Zinc and Number of Dips 

{Clauses 7.1 and 7.2.1 ) 



Nominal 




Light Coated Wire 








Heavy Coated Wire 




T\itt 


meter 


^ — 


— \ 




— » 
















uia 


f 






N 




of Electro- 
Galvanized 
Wire 


Soft 

... ^ 




Hard 






Soft 






Hard 

A_ 




Mass of 


Number Mass of 


Number Mass of 


— 1 r 

Number JMass of 


Number 




> 


Coating 

g/m* 


of Din<B Cnatino 


of Dips 


(^Afitino 


of Dins f^natinrw 


of 


Dips 


Above 


Up to and 


, ^ 


— — ^ 


g/m« 




g/m» 




-* 1 g/m« 


1 




"' 


^ — 1 




Including 




1 


4 




1 


i 




1 


i 




1 


i 








min 


min 




min 


min 




min 


min 




min 


min 


(I) 


(2) 


(3) 


(4) 


(5) 


(6) 


(7) 


(8) 


(9) 


(10) 


(11) 


(12) 


(13) 


(14) 


0-200 


0-315 


20 


No test 


No test 


15 


No test 


No test 


45 


No test 


No test 


45 


No test No test 








requir- 


requir- 




requir- 


requir- 




requir- 


requir- 




requir- 


requir- 








ed 


ed 




ed 


ed 




ed 


ed 




ed 


ed 


0315 


0400 


20 


do 


do 


15 


do 


do 


70 


do 


do 


70 


do 


do 


0-400 


0-500 


20 


do 


do 


15 


do 


do 


90 


do 


— 


90 


do 


do 


0-500 


0-560 


30 


do 


do 


20 


do 


do 


100 


— 


1 


100 


do 


do 


0-560 


0-63 


30 


do 


do 


20 


do 


do 


110 


— 


1 


110 


do 




0*63 


0-71 


30 


do 


do 


20 


do 


do 


120 


— 


1 


120 


do 




0-71 


80 


30 


do 


do 


30 


do 


do 


140 


— 


1 


140 


do 




0-80 


0-90 


40 


do 


do 


30 


do 


do 


150 


— 


1 


150 


do 




0-90 


1-00 


40 


do 


do 


40 


do 


do 


170 







150 






I 00 


1-25 


40 


do 


do 


40 


do 


do 


180 




— 


160 




— 


1-25 


1-40 


50 


do 


do 


40 


do 


do 


200 




— 


180 




— 


1-40 


1-60 


60 


do 


do 


50 


do 


do 


210 




— 


190 







1*60 


1-80 


60 


— 


1 


60 


do 


do 


230 




1 


200 




— 


1*80 


2-00 


70 


— 


1 


60 


do 


do 


240 


2 


— 


210 




— 


200 


2-24 


70 


— 


1 


60 


do 


do 


240 


2 


— 


210 




— 


2-24 


250 


80 


— 


— 


70 


do 


1 


260 


. 2 


— 


230 




1 


2-50 


2-80 


90 




— 


70 


do 


1 


260 


2 


— 


230 


2 


1 


2-80 


3-15 


100 




: — 


70 


do 


1 


270 


2 


1 


240 


2 


— 


315 


3-55 


110 




— 


80 


do 


1 


270 


2 


1 


250 


2 


— 


3-55 


4-00 


120 




_ 


90 


1 


do 


280 


2 


1 


260 


2 


1 


4-00 


5-00 


130 




— 


100 


1 


do 


290 


2 


1 


275 


2 


1 


500 


7-10 


140 




— 


110 


1 


do 


290 


2 


1 


290 


2 


1 


7-10 


100 


140 




— 


110 


1 


do 


300 


3 


— 


300 


3 


— 



IS 12753 : 1989 



Table 2 Requirements for Medium ( Z-Type ) 
Electroplated Coatings of Zinc 

( Clauses 7.1 and 7.2.1 ) 



Table 3 Requirements for Adhesion Test 
( Clause 8.1.2) 



Nominal Diameter 
Galvanized Wire, 

mm 

(1) 
0-200 and Up 
0-315 



of 



Above 



0-400 

0-500 

0-560 

063 

0-71 

0-80 

0-90 

roo 

1-25 
1-40 
1-60 
1-80 
2-00 
2-24 
2-50 
2-80 
3-15 
3-55 
4-00 



to 0-315 
0-400 
0-500 
0-560 
0-63 
0-71 
0-SO 
0-90 

roo 

1-25 

1-40 
1-60 
1.80 
2-00 
2-24 
2-50 
2-80 
3-15 
3-55 
400 
500 



Mass of 
Coatins 

g/m'» 

(2) 

30 

35 

45 

60 

60 

60 

75 

75 

75 

90 

90 

95 

95 

105 

105 

110 

120 

120 

135 

135 

150 



Number of Dips 



1 min 
(3) 



i min 
(4) 



electroplaters responsibility for defects in the 
zinc coating, resulting from such conditions 
shall be waived. 

8 ADHESION OF ZINC COATING 

8.1 Test Specimen 

8.1.1 The test specimen consists of a piece of 
wire, long enough to allow the test to be carried 
out properly. 

8.1.2 The test specimen shall be wound round a 
cylindrical mandrel so as to form close spirals as 
specified in Table 3. 

8.2 Procedure 

8.2.1 Winding shall be carried out at a rate not 
more than 15 turns per minute. 

8.2.2 When so wound or bent around the man- 
drel, the zinc plating shall remain adherent to 
the steel wire and shall be considered as meeting 
this requirement if owing to such winding or 



Nominal Diameter 
of Wire 

mm 
Up to and including 

3-55 
Over 3"55 upto and 

including 7- 10 
Over 710 



Minimum Complete 
Turns of Wrap 



10 



10 
i ( one 90° bend ) 



Ratio Between 
Mandrel Dia- 
meter and of 
Wire 

4 



bending, the plated coating does not flake off 
nor crack to such an extent that there is possibi- 
lity of removing any zinc by rubbing with bare 
fingers, the use of nail being not allowed. 

8.3 The electrogalvanized coating shall not flake 
off, when subjected to dry or wet drawing. The 
total reduction should be minimum 20 percent. 

9 SAMPLING 

9.1 The 

samples 
ing plan 
wire or 
absence 
shall be 
zer and 



size of the batch and the number of 
to be selected shall be as per the sampl- 
specified in the standard governing the 
article fabricated from wire. In the 
of such standard, the degree of sampling 
as agreed to between the electrogalvani- 
the purchaser. 

9.1.1 Coil for testing shall be selected by the 
purchaser. 

9.1.2 Portions of wires which are obviously 
damaged shall not be used as samples. 

9.2 Batch 

For the purpose of this standard a batch shall 
consists of wires of same dimensions processed 
together from pretreatment to final electrogalva- 
nizing. 

10 RETEST 

10.1 If the batch sample fails to meet any of the 
requirements of this standard, double the num- 
ber of samples, further shall be tested for each 
failure and if any of the sample fails, the batch 
shall be treated as rejected. 



ANNEX A 
( Foreword ) 

GENERAL GUIDANCE FOR APPLICABILITY OF TYPE OF COATING FOR 

DIFFERENT APPLICATIONS 



Application 



Type of Coating 

A 



Heavy 

Fencing wire x 

Stay strand wire X 

Signal strand wire X 

Chain link wire X 

Rope wire X 

Spring wire — 

Cable armouring wire X 

ACSR wire X 

Mild steel wire X 



Light 
X 



Medium 



Application 



Telephone wire 
Cycle spoke wire 
Barbing wire ( line ) 
Barbing wire ( point ) 
P.C. wire 

Lighting conductor 
wire 

Rubber hose rein- 
forcement wire 



Type of Coating 

Heavy Li^ht Medium 

X — — 

— X — 

XX — 

— X — 
X — — 
X — — 

XX — 



X Applicable, — Not applicable. 



Standard Mark 

The use of the Standard Mark is governed by the provisions of the Bureau of Indian 
Standards Act, 1986 and the Rules and Regulations made thereunder. The Standard Mark on 
products covered by an Indian Standard conveys the assurance that they have been produced 
to comply with the requirements of that standard under a well defined system of inspection, 
testing and quality control which is devised and supervised by BIS and operated by the pro- 
ducer. Standard marked products are also continuously checked by BIS for conformity to 
that standard as a further safeguard. Details of conditions under which a licence for the use 
of the Standard Mark may be granted to manufacturers or producers may be obtained from 
the Bureau of Indian Standards. 



Boreao of Indian Standards 1 

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to 
promote harmonious development of the activities of standardization, marking and quality 
certification of goods and attending to connected matters in the country. 

Copyright 

BIS has the copyright of all its publications. No part of these publications may be reproduced in 
any form without the prior permission in writing of BIS. This does not preclude the free use, in 
the course of implementing the standard, of necessary details, such as symbols and sizes, type or 
grade designations. Enquiries relating to copyright be addressed to the Director ( Publications ), BIS* 

Refision of Indian Standards 

Indian Standards are reviewed periodically and revised, when necessary ^and amendments, if any, 
are issued from time to time. Users of Indian Standards should ascertain that they are in possession 
of the latest amendments or edition. Comments on this Indian Standard may be sent to BIS 
giving the following reference: 

Doc:No. MTD20(3161) 



Amendments Issued Since Publication 



Amend No. 



Date of Issue 



Text Affected 



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